WO2013143584A1 - Device and method for the automatic generation of power-up sequences in an installation - Google Patents

Description

description

Device and method for the automatic generation of switch-on sequences in a system

Industrial plants, also called automation systems, are used for the automated production of products and for the automated execution of processes. Depending on the requirements of the system, they are composed of many small and large components. In these components a variety of functionalities, such as measuring, controlling, controlling, the operation of the components via interfaces and the communication between the components and the interfaces reali Siert. The components may be individual machines, conveyor units or entire manufacturing cells with internal structure. There are also dependencies between these components, which prescribe, for example, that a particular component can not be switched on or off until one or more other components are in a defined state.

The raising or lowering of such a complex system is a process that extends for a long period of time as well as done manually, because the ^¬ game of components is too complex to program a sequence sequence explicitly.

As a result of these circumstances, the individual components do not produce anything during downtimes of this plant, but they are still in working order, so that a considerable amount of energy is still consumed. Investigations by automobile manufacturers have shown that the energy consumption of a non-producing plant is up to 60 compared to a plant in the producing plant. There is a huge savings potential here. In addition, it is usually not known which components in which states consume how much energy and which times are required for state changes. Thus, the prerequisite is missing to assess whether it makes sense certain parts of the system, eg. B. during short breaks off.

Also switching to energy-saving conditions, eg. As standby, is not made today, since such conditions in the Anla ^¬ ge are not provided and implemented. In addition, switching to such states would require knowledge of the dependencies in the plant.

State of the art

The commissioning of a plant is done manually by experi ^¬ renes staff. Switching off and switching on producti ^¬ onsanlagen after the first start-up is now usually omitted because, it is necessary to manually perform the switching operations of the individual components special staff with very detailed knowledge of the dependencies of the various components to each other and how these are to be synchronized. If anything, systems are shut down only in too long non-productive times, for example during plant holidays. Restarting the system then takes many hours and can only be done by a few people.

In another application, a device for controlling a system or a part of a system consisting of system components is proposed. The controller uses a structural model of the plant as well as state models of the components contained in the plant. The models used also include information on possible conditions which the system components can assume and on the respective energy consumption of the components in the respective state. Together with further information about logical dependencies between the individual components in the respective energetic states. Being logical dependencies understood here in the following that a shift of at least one plant component requires more states of other Anla ^¬ gen components to control ordered a plant or Anla ^¬ contrary.

By knowing the dependencies between the components of the system, it is (the Energieschaltcont ^¬ roller) of the device possible to switch each component in its various states. Thus the plant in predefi ^¬ ned total states can (are made up of combinations of the states of the components) are switched. This is not only the system can on and off automatically ^¬ to, but it can also defined energy-saving stands to ^¬ in non-productive operation, so-called standby states, as well as energy-saving states in production, for example,

Part load operation, to be approached.

It is an object of the invention to provide a method and a device, with the aid of which a system can be switched as energy efficient as possible in an active productive operation.

The object is achieved by a method according to patent claim 1 and a device according to patent claim 6. The method according to the invention establishes an on or off sequence for plant components in an industrial plant, wherein each of the plant components has logical dependencies one or more other plant components, and in which these dependencies are to be considered in the turn-on order, and for each plant component information about a component-specific energy absorption course during the period of the power-on process are known and during the Einschaltvor ^¬ gangs the total energy consumption in the industrial plant always below a predetermined energy threshold remains The device according to the invention for establishing an on or off sequence of system components in an industrial installation, in which each of the system components can have logical dependencies on one or more other system components, and in which these dependencies at the switch-on The sequence to be observed, wherein for each system component information about a component-specific energy absorption during the period of the power-on process are known and ensures that the total energy consumption in the. By the appropriate selected sequence during the ermit ^¬ ted switching on or off always remains below a predetermined energy threshold

Further advantageous embodiments are specified in the subclaims.

The timing of energy consumption when a component is switched on can vary considerably, depending on the type (s) of consumers. For some components (eg, machines or entire manufacturing cells), the load history may be very complex. When switching on several load peaks can occur. If different components simultaneously turned ^¬ switches so there may be an unwanted addition of load peaks are the allowed limits exceed and z. B. Trigger fuses in the system.

Since the exact chronological course of the energy consumption of components in a system is largely unknown, the components are started one after the other with a large safety margin. This results in very long start-up times for a system.

The automatically determined total energy consumption allows the switch-on or switch-off sequence to be shortened in time without violating the required boundary conditions such as dependencies or maximum permissible energy consumption. The energy curve of the respective components (profiles) can be determined by the supplier of a component or must be measured in the system itself.

The advantage of this control of the switching sequence is a time-optimized sequence to turn on or off a plant or even a part thereof. Based on this data can z. B. decide a parent energy management system in downtime, whether the shutdown of the system or parts of it is possible to have at the end of time again a fully operational system.

The present invention will now be explained in more detail with reference to the attached figures.

Figure 1 is a first load curve when switching a system Figure 2 shows a second load profile when switching a system according to the inventive method

3 shows an overview of a parent Energiemana ^¬ management system with interfaces

4 shows a system with subsystem.

The following figures 1 and 2 show by way of example the energy consumption of three different components of a plant. It can be seen that at the start of the components K1, K2, K3 (eg a production cell) one or more

Consumption peaks 11, 21, 31 occur. If the three components are started at the same time, it can clearly be seen in the diagrams of FIG. 1 that in the total consumption KG at time S, a peak value arises which is the permissible one

Exceeds limit G by approx. 25%.

Now the variation of the energy consumption of the components is analyzed and ensured by a calculated time and opti mized ^¬ switching sequence for the components in consideration of the logical and temporal dependencies of the individual components to be controlled Kl, K2, K3, that the limit is not exceeded and in this example a safety of approximately 25% is maintained. For this purpose, according to the diagrams of FIG. 2, the components are not all started up at the same time, but are started offset in time at the times ZI, Z2 and Z3. Here are logical from ^¬ dependencies to the effect to be considered that ensures that system components that are required for the proper operation of other system components (eg, cooling) are first turned on and loading already available when its dependent component into production is driven. In the example shown, this leads to the fact that the component K3 is started before the component K2.

FIG. 3 shows an overview of an exemplary energy management system for carrying out the method ^according to the invention. Shown are the generic functions of the ei ^¬ tual control, decision logic, the calculation of their control commands based on the structure of the steu ^¬ ernden plants (parts), structural model of the system, and the or the state definition of the respective components, General State Model 1-4 , Further information can be available on state transitions, 17, dependencies, 18, and further information on the transitions, 19, 19 '.

In an energy management system / energy switching controller, the time profiles of the energy consumption of the different ^¬ components of a system can be defined and stored. These may have been determined automatically or, for example, initially supplied by the manufacturer. In addition, limits for certain parameters, eg. B. load, be deposited.

A power-up sequence is calculated loading of power switching controller, which takes into account the dependencies of the various components to each other and the summary values for example, the load bearing so that an over ^¬ underrange predetermined limit values, eg maximum load receiving, is prevented. It is calculated while the shortest possible switching sequence. This is advantageous since the Ge ^¬ complete system of the plant can remain in an energy-saving stand-by mode as long as possible and only short of the desired productive time (when all components are again available) are driven high.

The power switching controller ESC, 1, can be used by many other systems. For this he has a suitable

Interface to higher-level systems, 14.

 A few possible examples of such systems are:

 • A Product Planning System, 21, and an MES system are aware of break times and company breaks. They use the power switching controller, 1, to switch to the most energetic state for the known breaks while ensuring that the system is available again when it is needed again.

• A fault management knows that the disruption of a part of the plant means that other parts of the plant are no longer needed at the moment, as they are no longer needed. B. get no more parts delivered. Now the fault management using the Energieschaltcont ^¬ rollers can send these unneeded equipment parts in an energy ^¬ saving standby state. Presumably, it must be ensured that the system components can be "reawakened" within a certain time, ie can be switched back to productive operation.

 • A load management system, 23, or in the future a command response controller with a connection to a smart grid, should be able to switch parts of the system off or into standby states for peak load control.

For this purpose, these systems can first be determined by the energy ^switching controller 1, in which states and with which power consumption the system and its components are currently running. In addition, it can determine in which states (productive or non-productive) the individual components can be switched. With the help of specifications (which, of course, also the dependencies that can be determined by the power switch controller considered) load management system can now call on the power switch controller to drive the entire system or parts thereof (in energy-saving states or between non-productive ^{¬-productive).}

· A material handling system knows that due to different speeds and buffers in the system, or due to redundant system parts, some parts of the system are only used intermittently. Since it also knows when and how long these parts of the system are used or not used, such parts (must, of course, as components in the

Energy switching controller be modeled) are switched over the power switching controller for the time of Nichtverwendung in the most energetically favorable state. Also, such system parts could be in partial operating conditions, eg. For example, slower products can be switched.

A corresponding control of the affected equipment / plant components / components 31, 32, 33, 34 then takes place via plant-specific interfaces, 15. Specific adjustments are required. The connection of the components is possible in various ways, for example, four different possibilities are shown here:

 • by means of specific programmed access to the component PLC1,

· Via a standardized communication protocol OPC UA

• with direct access - function block)

• In addition to general state model can also be a local state model on the component PLC4 behind ^¬ puts his.

FIG 4 illustrates an Example exemplary energy management system with partial plant. As a further advantage of the standardized interface of shut-off / control function and on Controllerebe ^¬ ne (for example via an interface Profienergy Vx) can be considered. The parameterization of the energy switching

Controllers ESC, as described below, means that when changing the conditions in the system, the program itself does not have to be changed or only minimal, but only the parameters, so the definitions of the model definitions of the system and / or components and or the states and state transitions of the Anla ^¬ ge / plant components. There, 101, among other things, the monitoring and parameterization is performed. Furthermore, any change that is required, for example, in a device replacement, entered here, as well as a possible manual operation.

Via the interface 4, a communication to the higher-level systems can take place, if available. For example, to the MES 21, regarding breaks, company breaks and production plans. The fault management 24, and the load management 23 for switching off at peak loads. In the one illustrated component, machine 2, an energy state model 332 is shown by way of example. This is already included in the component.

Claims

claims 1. Method for Creating an On or Off Sequence for Plant Components in an Industrial Plant,  in which each of the plant components may have logical dependencies on one or more other plant components, and  in which these dependencies are to be observed in the switch-on sequence, and  for each plant component, information about a component-specific energy absorption course during the period of the switch-on process is known and during the switch-on process, the total energy consumption in the industrial plant always remains below a predetermined energy threshold value 2. The method according to claim 1, characterized in that  the period in which the determined switch-on process from the start of the first plant component to the productive time of the plant, or vice versa, is minimal. 3. The method according to any one of the preceding claims, characterized in that the information on the component-specific Ener ^¬ gieaufnahme during the period of the turn-on operation are already known in the equipment component. 4. The method according to any one of the claims 1 or 2, characterized in that the information on the component-specific Ener ^¬ gieaufnahme during the period of the turn-on operation in the components must be ^¬ telt ermit first within the system. 5. Method according to one of the preceding claims for energy-efficient control of the switch-on sequence of the components, (31, 32, 33, 34),  characterized in that with - a stored structural model (12) of the control ^¬ the plant or plant part, comprising encompassed by the system components (Komponentel, ...),  at least one stored state model (13a,  13d) of at least one component included in the plant or in the plant part (components 2, 3, 4),  possible energetic or functional states of the components, as well as possible state transitions between the individual component states, and - stored dependencies between from the plant  or parts of the plant (components, ...) are used based on the structural model, the at least one state ^¬ model, the possible states of the components contained and possible state transitions between the component's own states, the dependencies between the components as well as the information on a component-specific energy consumption during the period of the power-on operation, a calculation an automated control sequence of the individual system components according to the specifications bach one of claims 1 to 5 takes place (31, 32, 33, 34). 6. Apparatus for establishing an on or off sequence of plant components in an industrial plant,  in which each of the plant components may have logical dependencies on one or more other plant components, and  in which these dependencies at the switch-on Order to follow, wherein for each plant component information about ei ^¬ ne component-specific energy absorption during the period of the power-on process are known and during the power-up the total energy consumption in the industrial plant always remains below a predetermined energy threshold Device (1) according to claim 6, characterized in that - means for storing a structural model (12) of the controlled plant or plant part, be ^¬ standing out from the system included components (31, ..34),  Means for storing at least one state model (general state model 1 -4, 13a,... 13d) of the components (31,... 34) included in the plant or in the plant part,  Means for storing energetic or functional states actually associated with the components and possible state transitions (17) between the individual component states,  - means for storing dependencies (18) between components comprised by the plant or the plant part (31, ..34), and  - Decision logic (11) for the evaluation of all stored information and the information on the component-specific energy absorption course during the period of the on or off operation.